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PRODUCT DATA SHEET
Dry-Break Diesel Refuelling Nozzles
Banlaw ReFuelling™
Version 1.0 1/ 31 PRH-REF- 70
Thank you for purchasing this high quality Banlaw product. Please read through and
understand the information in this Product Data Sheet (PDS) BEFORE installation or operation
of the product to avoid accidental personal injury or property damage.
1 PRODUCT DESCRIPTION
Banlaw Dry-Break Diesel Refuelling Nozzles are fluid (e.g. diesel fuel) dispensing couplings which
incorporate both calibrated (automatic) pressure shut-off, and “dry break” functions.
Banlaw introduced their first dry-break diesel refuelling nozzles into the market in the 1980’s in
response to a requirement for a more ergonomic and robust “industry standard” nozzle rated for higher
diesel flowrates.
800 Series
1000 Series
Figure 1 - Examples of Banlaw Nozzles
Figure 1 shows examples of current Banlaw 800 and 1000 series Nozzles. The “800” refers to the
maximum rated diesel flowrate of 800LPM (211GPM) of the 800 series, and likewise the “1000” refers
to the maximum rated diesel flowrate of 1000LPM (264GPM) of the 1000 series.
Banlaw Nozzles are available in a variety of models (variants) within each series, including the Banlaw
FuelTrack™ Nozzles incorporating the Banlaw proprietary automatic (vehicle) identification – i.e. “auto
ID” – feature. Banlaw Nozzles also incorporate other features including the patented# means of
adjusting the automatic shut-off setting (# US 6,622,760).
The 800 series “Mining” Nozzles are compatible with the industry standard refuelling “receivers”,
commonly used as the means of refuelling plant equipment and smaller bulk diesel storage tanks in the
mining and construction industries. Other 800 series models – e.g. “Rail” – and Banlaw 1000 series
Nozzles are only compatible with the matching Banlaw receiver.
This document specifically covers the principal specifications, installation, commissioning, operation,
maintenance and servicing requirements and guidelines of Banlaw 2” (DN50) Diesel Refuelling and Fluid
Transfer Nozzles. End-users requiring additional information should refer to the Banlaw website,
contact Banlaw or your nearest authorised Banlaw distributor. Similarly, persons wanting information
other Banlaw refuelling products and Nozzle accessories should also refer to the website or same
contacts.
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 2/ 31 PRH-REF- 70
CAUTION
The content of this document is not meant to override or substitute any
applicable Statutory, Regulatory, Customer/Site, etc. Health Safety &
Environment (HS&E) requirements.
All works should only be performed by trained, qualified and competent
personnel who are aware of the hazards associated with the constituent
components of this installation in addition to the “system” as a whole. Failure to
comply with these practices may result in death, serious bodily injury, loss of
equipment and environmental damage.
A risk assessment (job hazard analysis - JHA) should be conducted PRIOR to the
start of any works or actions within this document. Whilst every effort has been
made to ensure the execution of this document represents no HS&E hazard,
Banlaw takes neither responsibility nor liability for the consequences and
damages that may occur in the execution of works within this document.
Persons conducting or otherwise involved with the execution of the works within
this document and project have an obligation to ensure that all HS&E
requirements are known and understood, and subsequently followed at all times.
Contents 1 PRODUCT DESCRIPTION .......................................................................................................................................................................... 1
1.1 Glossary of Terms ................................................................................................................................................................................. 3
1.2 System Overview .................................................................................................................................................................................. 4
1.3 Key Features ......................................................................................................................................................................................... 5
1.4 Part Numbering .................................................................................................................................................................................... 6
1.5 Available Nozzle Models ....................................................................................................................................................................... 7
1.6 Nozzle Spring Settings .......................................................................................................................................................................... 8
1.7 FuelTrack Nozzle Variants................................................................................................................................................................... 10
1.8 Nozzle and Receiver Compatibility ..................................................................................................................................................... 11
2 IMPORTANT RESTRICTIONS ON THE USE OF THIS PRODUCT ................................................................................................................. 12
3 PRODUCT SPECIFICATIONS .................................................................................................................................................................... 13
3.1 Nozzle Flow Performance ................................................................................................................................................................... 14
4 INSTALLATION & COMMISSIONING GUIDELINES ................................................................................................................................... 15
4.1 Pre-Installation Guidelines ................................................................................................................................................................. 15
4.1.1 Nozzle – Ergonomics ................................................................................................................................................................ 16
4.1.2 Nozzle – Storage ....................................................................................................................................................................... 18
4.2 Installation Guidelines ........................................................................................................................................................................ 19
4.2.1 Banlaw FuelTrack Nozzles ........................................................................................................................................................ 20
4.3 Commissioning Guidelines ................................................................................................................................................................. 21
5 PRINCIPLES OF OPERATION ................................................................................................................................................................... 21
6 MAINTENANCE & SPARE PARTS ............................................................................................................................................................ 26
6.1 Preventative Maintenance ................................................................................................................................................................. 26
6.2 Banlaw Onsite Maintenance .............................................................................................................................................................. 28
7 TROUBLESHOOTING .............................................................................................................................................................................. 29
8 PRODUCT RECYCLING & DISPOSAL ........................................................................................................................................................ 31
9 PRODUCT WARRANTY ........................................................................................................................................................................... 31
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 3/ 31 PRH-REF- 70
1.1 Glossary of Terms
The following glossary defines key terms used within this document.
Dry-Break An industry term used to describe a fluid coupling which is of the “normally closed”
or liquid tight state whilst ever this coupling remains disconnected from its mating
coupling. Fluid (fuel) pressure may exist within the coupling, although no fluid
discharge may occur whilst the coupling remains in the normally closed (dry-break)
state.
Nozzle A female refuelling coupling (coupler) – sometimes referred to as a “fuel gun” -
normally attached to the end of the dispensing (supply) line (e.g. dispensing hose).
A Nozzle engages with a Receiver to form a sealed (liquid-tight) connection for the
pressurised transfer of a liquid (e.g. diesel).
Receiver A male refuelling coupling (coupler), normally attached to the inlet of the vessel to
be filled via the Nozzle.
Tank Vent For the purposes (scope) of this document, a Tank Vent (or Vent) shall refer to a
Banlaw Vent (or Vent of same kind) specifically designed to be compatible with the
Banlaw quick-fill refuelling system.
Quick-Fill An industry term used to describe a complete dry-break diesel refuelling system,
consisting of a Nozzle, Receiver and Tank Vent(s). This system is the same kind as
the Banlaw refuelling system, specifically a system which relies on the closure of
the Tank Vent(s) once the Tank(s) is refilled, the short-term pressurisation of the
Tank(s), and the automatic shut-off (i.e. closure) of the Nozzle.
Overfill
Protection
(OFP)
Refers to a system designed to supplement (complement) a Quick-Fill System, but
where the OFP system acts as the primary (first) means of terminating the inflow
of liquid into the tank without the need for pressurisation of the tank(s).
Flash Point (FP) “The lowest temperature, corrected to a barometric pressure of 101.3kPa(a) (i.e.
1 atm), at which application of a test flame causes the vapour of the test portion
to ignite under the specified conditions of the test.” [AS1940-2004].
Combustible
Substance
(Liquid)
“Any liquid, other than a Flammable Liquid, that has a Flash Point, and has a Fire
Point that is less than its Boiling Point.” [AS1940-2004]. Other definitions denote a
combustible liquid as having a Flash Point of >60.5°C (>140.9°F). In addition;
“Combustible liquids that are stored, handled or processed at a temperature T ≥
(FP−6°C) should be considered as flammable liquids. Zonal (hazardous area)
distances for such liquids should be determined accordingly in accordance with
this Standard unless a detailed classification indicates otherwise.” [AS/NZS
60079.10.1-2009 ZA.5].
Flammable
Substance
(Liquid)
“Liquids, or mixtures of liquids, or liquids containing solids in solution or
suspension which give off a flammable vapour at temperatures of not more than
60.5°C (140.9°F), closed cup test, or not more than 65.6°C (150.1°F), open cup test,
normally referred to as the Flash Point.” [AS1940-2004]. In addition; “Combustible
liquids that are stored, handled or processed at a temperature T ≥ (FP−6°C)
should be considered as flammable liquids.
Diesel Fuel Clean (filtered) automotive grade diesel fuels, including summer and winter
blends. Excludes heavy distillates, e.g. bunker oils, heavy fuel oils (HFO), etc.
Explosive
Atmosphere
“Mixture with air, under atmospheric conditions, of flammable substances in the
form of gas, vapour, dust, fibres, or flyings which, after ignition, permits self-
sustaining flame propagation.” [AS/NZS 60079.10.1-2009].
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 4/ 31 PRH-REF- 70
Hazardous Zone “An area in which an Explosive Atmosphere is or may expected to be present, in
quantities such as to require special precautions for the construction, installation
and use of equipment.” [AS/NZS 60079.10.1-2009]. The classification of a
Hazardous Zone is conducted in accordance with the governing Standards –
typically specific to regions/countries, in the absence of universal (harmonised)
Standards.
Spring Setting Within this document “spring setting” applies to the setting of the automatic shut-
off (closure) feature of a Nozzle. This feature is responsive to liquid (i.e. diesel)
pressure within the Nozzle and can be adjusted by changing the specification of
the Piston Spring within the Nozzle and/or the specification of the Poppet Spring
within the Receiver. In simple terms, increasing the spring setting will increase the
liquid pressure at which the Nozzle will automatically shut-off, and decreasing the
spring setting will decrease the pressure required for shut-off.
1.2 System Overview
Banlaw Dry-Break Diesel Refuelling Nozzles are a key component used in “quick-fill” refuelling systems.
Banlaw Nozzles provide a means of fuel shut-off and are often used in systems incorporating storage
tank Overfill Protection (e.g. Banlaw FillSafe™ Zero, FillSafe Power) and fluid asset management systems
(i.e. Banlaw FuelTrack™ Banlaw ResTrack™).
Figure 2 – Example of a “Pressurised Tank” Refuelling System
The example shown in Figure 2 is a basic “quick-fill” tank refuelling system incorporating Banlaw Nozzle,
Receiver, and Tank Vent. The means of fuel flow shut-off in such systems is by closure of the Vent,
(internal) pressurisation of the tank, and automatic shut-off (closure) of the Nozzle. Incorporating a
Banlaw FuelTrack Receiver provides a means of identifying the unique asset “tag” (code) of the tank
within the FuelTrack or ResTrack system.
The example shown in Figure 3 is a refuelling system using a separate means of tank OFP – specifically
a Banlaw FillSafe™ Zero system. In this example, the Banlaw “pressurised tank” system acts as a backup
in the unlikely event the primary OFP fails.
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 5/ 31 PRH-REF- 70
Figure 3 – Example of a “Pressurised Tank” Refuelling System with Separate OFP
1.3 Key Features
Since their inception, Banlaw refuelling nozzles have evolved as a key part of Banlaw’s commitment to
innovation and continuous improvement. Considered a market leader, Banlaw nozzles provide industry-
leading standards of safety, reliability, durability and serviceability. Designed to provide an extended
service life, some of the earliest generation of Banlaw nozzles are still being serviced and returned into
operation!
Key advantages of Banlaw nozzles include;
• Patented means of adjusting the automatic shut-off (closure) setting, accommodating a wider
variety of refuelling applications.
• Banlaw 800 model “Mining” series Nozzles (e.g. BNM800M) suit all industry standard Receivers,
e.g. Wiggins ZN2 & JNX series, Caterpillar, FloMAX FR series, etc.
• Industry-proven ball lock latching mechanism, providing superior safety and durability.
• Wearing and structural parts manufactured from metals, not plastic.
• Parts manufactured from stainless steel for superior durability.
• Serviceable by accredited (trained) Nozzle Repair Agents in most regions and countries.
• “Arctic” (cold temperature) models available for safe and reliable operation in extreme cold
climates.
• High quality OEM fluid seals used in all dynamic sealing applications, not inexpensive O’Rings.
• Manufactured, assembled and factory tested in accordance with Banlaw’s ISO9001 certification.
Every nozzle is traceable by its serial code.
• Banlaw FuelTrack™ models available to support the automatic identification (auto ID)
functionality of a Banlaw FuelTrack or ResTrack system – arguably the most secure fuels and
resource management system of its kind available in the market.
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 6/ 31 PRH-REF- 70
Figure 4 illustrates the overall dimensions (millimetres, mm) of a Banlaw refuelling nozzle;
Conversion; 1mm ≈ 0.039”, i.e. 25.4mm = 1”.
Figure 4 - Overall Dimensions of an 800 Series Banlaw Refuelling Nozzle
Figure 5 illustrates the key external features of a Banlaw refuelling nozzle.
Figure 5 - Key External Features of Banlaw Nozzle
1.4 Part Numbering
Figure 6 and Figure 7 denotes the part numbering system used for Banlaw nozzles currently available.
Earlier (superseded) Banlaw nozzles were assigned a different part number – if required, please contact
Banlaw for details. Refer to section 1.6 for important information on Nozzle Spring Settings.
OPERATING “T” HANDLE
CARRY “D” HANDLE
ACTUATOR
DUST PLUG
HANDLE CATCH
NOZZLE INLET 2” NPT (F)
NOZZLE OUTLET
FRONT
REAR
BUMPER BALL
LOCKS
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 7/ 31 PRH-REF- 70
Figure 6 - 800 Series Nozzle Part Numbering
Figure 7 - 1000 Series Nozzle Part Numbering
1.5 Available Nozzle Models
The 800 Nozzle series currently consists of 12 different models, whilst the 1000 Nozzle series consists
of 4 models – as per Table 1. Please refer to Banlaw Sales & Marketing material for further details.
800 Series 1000 Series
Standard FuelTrack Standard FuelTrack
BNM800 BNMF800 BN1000 BNF1000
BNM800-CT BNMF800-CT BN1000-CT BNF1000-CT
BNR800 BNRF800
BNR800-CT BNRF800-CT
BNH800 BNHF800
BNH800-CT BNHF800-CT
Table 1 - Nozzle Models
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 8/ 31 PRH-REF- 70
NOTES: 1. Not all Models are available ex-stock and are made to order.
2. Each Model is available with select spring (i.e. shut-off pressure) settings. Not every spring
setting is available in each Model.
3. Nozzle availability is subject to change – please refer to the Banlaw website or contact Banlaw
or your nearest authorised Banlaw distributor for the most up to date details.
Figure 8 illustrates the location on a Nozzle where the model and unique serial code details are marked.
Figure 8 – Example of Model and Serial Details on Right Side of Nozzle
1.6 Nozzle Spring Settings
Each Nozzle is available with a pre-set spring setting, specifically the setting (specification) of the piston
spring. Banlaw document EBL-33 provides further important information on spring settings.
Selection of the required Spring Setting should be performed prior to purchase of a
Nozzle. Any adjustment of the Spring Setting within a Nozzle must only be
conducted by Banlaw or a Banlaw authorised Nozzle Repair Agent. The use of a
Nozzle with an inappropriate Spring Setting is potentially unsafe, and likely to
increase the risk level of hazards such as:
• Overfilling of the tank(s).
• Internal over-pressurisation of the tank(s).
• Fuel spillage.
• Personal injury, fire, or explosion.
Please conduct Banlaw for information on Nozzle Spring Settings.
“IF IN DOUBT, ASK!”
Available spring settings are detailed within Table 2.
Shut-Off (Spring) Setting Nozzle Series
Setting Code/Marking 800 Series 1000 Series
Light L Medium-Light ML
Medium M Medium-Heavy MH
Heavy H
Extra-Heavy XH
Table 2 - Available Nozzle Shut-Off (Spring) Settings
Table 2 Legend: Yes (available) No (unavailable)
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 9/ 31 PRH-REF- 70
Figure 9 is a simplified diagram illustrating the interface between the nozzle and receiver during
refuelling and the forces involved in opening or closing the nozzle.
Figure 9 - Simplified General Arrangement of Nozzle and Receiver Interface
Figure 10 provides a basic illustration of the relationship between Nozzle and Receiver spring settings.
Figure 10 - Relationship Between Nozzle and Receiver Spring Settings
Figure 11 illustrates the location on a Nozzle where the Spring Setting is marked.
Figure 11 - Example of Spring Setting Marking on Top of Nozzle
For a given Nozzle spring setting, the effective (actual) liquid pressure at which the automatic shut-off
mechanism of a Nozzle is activated is dependent on several factors, including;
• Spring setting of the Receiver onto which the Nozzle is connected.
• Make (OEM) of Receiver.
• Liquid flowrate.
• The working condition of the Nozzle, i.e. whether the Nozzle is operating within the applicable
specifications for an “as new” (i.e. compliant) Nozzle.
“M” (MEDIUM)
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 10/ 31 PRH-REF- 70
Table 3 details the relationship between the various Nozzle settings, specifically with respect to the
“Medium” (M) setting. I.e. the “offset” refers to the change in nozzle shut-off pressure from a Medium
setting. This data only applies when the Banlaw Nozzle is used with a Banlaw Receiver and the Receiver
spring setting remains unchanged. The data may be subject to change when a nozzle is used with a non-
Banlaw (third party) receiver.
Nozzle Spring Setting Code/Marking Nozzle Shut-Off Pressure Offset (± 5 kPa)
Light L -40 kPa (5.8psi)
Medium-Light ML -20kPa (2.9psi)
Medium (Standard) M 0 kPa
Medium-Heavy MH +10 kPa (1.5psi)
Heavy H +25 kPa (3.6psi)
Table 3 - Nozzle (Piston Spring) Shut-Off Settings
Examples;
• Adjusting the Nozzle spring setting from a Medium (M) to a Light (L) setting will decrease the
shut-off pressure by 40 ± 5 kPa.
• Adjusting the Nozzle spring setting from a Medium (M) to a Heavy (H) setting will increase the
shut-off pressure by 25 ± 5 kPa.
Please refer to the Product Data Sheet (PRH-REF-72) for information on Receiver spring settings.
1.7 FuelTrack Nozzle Variants
Figure 12 illustrates the basic architecture of the Banlaw FuelTrack dry-break auto ID system, specifically
the Nozzle and Receiver in the 2 operating states;
• Nozzle disconnected from Receiver;
o 4.6 to 5Vdc at the centre contact of the Nozzle.
o Receiver is passive.
o No auto ID circuit.
• Nozzle connected to Receiver;
o Auto ID circuit energised between Nozzle and Receiver.
o Circuit “reads” unique ID tag (code) of Receiver. The Signal from the auto ID circuit is
transmitted through the active data cable and is Received and processed by the Local
Controller (i.e. “Depot”).
Most refuelling applications utilising a Banlaw or similar Nozzle are accommodated
using a “Medium” (M) spring setting, however growing use of larger plant equipment
and higher refuelling flowrates is creating a requirement for heavier (higher) Nozzle
spring settings. In addition, the use of non-metal (i.e. plastic, resin) fuel tanks are often
best refilled using a lighter Nozzle spring setting. Please refer document EBL-33.
To provide the highest practicable level of protection, Banlaw recommends a suitable
zero pressure overfill protection (OFP) system – e.g. Banlaw FillSafe™ is considered
for all tanks.
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 11/ 31 PRH-REF- 70
Figure 12 - Basic Operation of the Banlaw Dry-Break Auto ID System
1.8 Nozzle and Receiver Compatibility
Table 4 details the cross-compatibility of Banlaw Nozzles and the various Receivers available.
BANLAW NOZZLE & RECEIVER COMPATIBILITY
Nozzles Series Receivers Series
Banlaw 800 “Mining”
Banlaw 23 “Mining”
Wiggins ZN2, JNC2, JNX, etc.
Caterpillar
FloMAX International FR, FRA, FRS, etc.
Fast Fill Systems R150, R150CV, etc. # See also Note 1 (below)
Banlaw FuelTrack 800 “Mining” Banlaw FuelTrack 23 “Mining”
# See also Note 2 (below)
Banlaw 800 “Rail” Banlaw 23 “Rail”
Banlaw FuelTrack 800 “Rail” Banlaw FuelTrack 23 “Rail”
Banlaw 800 “Hydraulic” Banlaw 23 “Hydraulic”
Banlaw FuelTrack 800 “Hydraulic” Banlaw FuelTrack 23 “Hydraulic”
Banlaw 1000 Banlaw 43
Banlaw FuelTrack 1000 Banlaw FuelTrack 43
Table 4 - Banlaw Nozzle and Receiver Compatibility
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 12/ 31 PRH-REF- 70
NOTES: 1. Receiver OEM’s and Part Numbers subject to change. Banlaw 800 “Mining” series Nozzles will
also suit Receivers of the same type (basic design) manufactured by OEM’s not listed.
2. Banlaw FuelTrack 800 “Mining” series Nozzles will suit Receivers compatible with the Banlaw
800 “Mining” series Nozzles, however the automatic identification (auto ID) feature of the
FuelTrack (or Banlaw ResTrack) system will be inoperable.
3. The use of a Nozzle and Receiver combination deemed as incompatible is not condoned by
Banlaw and will create potentially serious safety and environmental hazards.
4. Applications where a Banlaw Nozzle is used with a non-Banlaw (i.e. third party) Receiver will
be subject to (i.e. governed by) specifications contrary to those of the Banlaw Nozzle – as per
section 3. In all such cases;
a. Minimum specification (lower threshold or limit); the highest specification nominated
by Banlaw or the Receiver OEM shall apply.
b. Maximum specification (upper threshold or limit); the lowest specification nominated
by Banlaw or the Receiver OEM shall apply.
2 IMPORTANT RESTRICTIONS ON THE USE OF THIS PRODUCT
1. The safe installation and subsequent operation of a Banlaw product relies on the
completion of all necessary “due diligences” for the assessment of the Banlaw
product(s) being suitable for the intended application(s). Such an assessment is
best achieved through the cooperation of the supplier/OEM (Banlaw) and the
customer or end-user. Once such an assessment deems the Banlaw product(s)
to be suitable, the customer or end-user shall ensure effective “change
management” applies should any prominent or influential aspect of the
application (upon which the initial assessment was based) be subject to change
and may affect the ongoing suitability (i.e. safety and proper function) of the
Banlaw product.
2. These Banlaw Dry-Break Refuelling Nozzles incorporate external and internal
components manufactured from aluminium. Products containing external
(exposed) aluminium are typically unsuitable for use within an underground
coal mine, or otherwise within an area where the use of external aluminium
components (or other materials within the product) are prohibited for use in
such areas in accordance with applicable governances.
1. During October 2010 Banlaw conducted a self-assessment (Banlaw document
EBL-19) of the Banlaw dry-break diesel refuelling Nozzles (and mating Banlaw
Receivers) under the requirements of the European Union (EU) Pressure
Equipment Directive (PED) 97/23/EC. The outcome of this assessment was that
these products do not require the CE mark when used in accordance with the
Banlaw product specifications. Unless noted otherwise by Banlaw, this product
has not been assessed under any other Regulatory or Industry Standard, Code,
Directive, Guideline or other governance which may apply to the use of this
product in applications where a governance applies. Please consult Banlaw prior
to installation if in doubt.
2. Please refer to Table 4 for details of compatibility of Banlaw Nozzles with Banlaw
and non-Banlaw Receivers. The use of a Nozzle and Receiver combination
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 13/ 31 PRH-REF- 70
deemed as incompatible is not condoned by Banlaw and will create potentially
serious safety and environmental hazards.
3. Banlaw Dry-Break Refuelling Nozzles are designed and tested for use with clean
(i.e. filtered) automotive grade diesel fuels, including commercial bio-diesel
blends. This Banlaw product is not recommended for use with waste diesel fuel,
or with diesel fuel containing contamination levels beyond those stipulated by
governances and guidelines such as the current Worldwide Fuel Charter (WWFC)
and fuel quality requirements of modern diesel engine manufacturers. The use
of this product with fuel of higher contamination levels may cause the improper
operation (failure) of the product and other detrimental effects. Banlaw
recommends adequate fuel contamination controls (e.g. filtration) for all fuels
passing through a Banlaw Nozzle;
a. The use of a Banlaw Nozzle with an alternate liquid type – e.g. a light oil
– may be conditionally acceptable after consultation with Banlaw.
b. Banlaw “Hydraulic” Nozzles (i.e. BNH800 series) have traditionally been
used with solcenic oils without incident.
4. Banlaw Nozzles are not recommended for use with AdBlue, corrosive, oxidizing,
acids, alkaline, solvents, flammable, explosive or gaseous (compressible) fluids or
with an alternative fluid (or substance) whose properties may affect the safety,
function or reliability of the product.
5. Specifically, for “Arctic” series Nozzles, noticeable physical changes (e.g.
clouding, additive drop-out, agglomeration, thickening, etc.) in the diesel fuel
passing through a Nozzle may cause reduced functionality of the Nozzle (and
associated Refuelling system).
3 PRODUCT SPECIFICATIONS
BANLAW 800 MODEL NOZZLES
Max. Diesel Flow Rate LPM
(GPM) 800LPM (211GPM)
Min. Flow Rate LPM (GPM) 90LPM (24GPM)
Operating Temp. Range °C (°F) -10°C (14 °F) to 55°C (131°F)
“Arctic” (-CT) series; -51°C (-60°F) to 55°C (131°F)
Max. Internal SWP kPa (psi) 2,000kPa (290psi)
Compatible Fluid Types Clean (filtered) Automotive Diesel Fuels, incl. Bio-Diesel
Blends. Refer also section 2.
Principal Material Composition Aluminium, Brass, Stainless Steel, Zinc Plated Steel, Viton®,
Nitrile (NBR), Acetal, Fluorosilicone, Nylon
Process Connection (Inlet) 2” NPT (F)
Mass of Nozzle (approx.) 3.9kg (8.6lb)
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BANLAW 1000 MODEL NOZZLES
Max. Diesel Flow Rate LPM (GPM) 1,000LPM (264GPM)
Min. Flow Rate LPM (GPM) 400LPM (106GPM)
Operating Temp. Range °C (°F) -10°C (14 °F) to 55°C (131°F)
“Arctic” (-CT) series; -51°C (-60°F) to 55°C (131°F)
Max. Internal SWP kPa (psi) 2,000kPa (290psi)
Compatible Fluid Types
Clean (filtered) Automotive Diesel Fuels, incl. Bio-
Diesel Blends
Refer also section 2.
Principal Material Composition Aluminium, Brass, Stainless Steel, Zinc Plated Steel,
Viton®, Nitrile (NBR), Acetal, Fluorosilicone, Nylon
Process Connection (Inlet) 2” NPT (F)
Mass of Nozzle (approx.) 4.2kg (9.3lb)
Legend: “SWP”; Maximum recommended Safe Working Pressure
“LPM”; Litres per minute (volumetric flowrate)
“GPM”; US Gallons per minute (volumetric flowrate)
“Max.”; Maximum (upper limit)
“Min.”; Minimum (lower limit)
Notes: 1. All pressure data refers to the internal fluid pressure, where each product is in “as new”
condition.
2. The core function of “Arctic” (CT) series Nozzles (and Banlaw Receivers) has been tested in an
independent laboratory at -51°C (-60°F) under the guidelines of MIL-STD-810G. These Nozzles
are fitted with fluid seals rated for operation below -60°C (-76°F).
3.1 Nozzle Flow Performance
Figure 13 illustrates the dynamic pressure drop (i.e. fluid head loss) through a Banlaw 800 model Nozzle
and Banlaw 23 model Receiver – refer also Notes below.
Figure 13 - Pressure Drop Through 800 Nozzle and 23 Receiver
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
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Figure 14 illustrates the dynamic pressure drop (i.e. fluid head loss) through a Banlaw 1000 model Nozzle
and Banlaw 43 model Receiver – refer also Notes below.
Figure 14 - Pressure Drop Through 1000 Nozzle and 43 Receiver
Notes: 1. All pressure drop data refers to the dynamic head loss through the Banlaw Nozzle and Banlaw
Receiver combination. This data will vary when a Banlaw Nozzle is used with a non-Banlaw
Receiver.
2. All data obtained using automotive grade diesel fuel at approx. 25°C (77°F). If comparing this
Banlaw data with other Nozzle OEM pressure drop data, ensure the fluid properties (density
and viscosity) are comparable with diesel fuel.
3. Data measured by flowrate and pressure measurement equipment calibrated in accordance
with Banlaw’s ISO 9001 certification.
4 INSTALLATION & COMMISSIONING GUIDELINES
This Installation & Commissioning Guide is general and is not meant to replace or override installation
guidelines that arise out of a due diligence assessment of a Banlaw product for a specific (intended)
application.
The scope of this section applies to this Nozzle, e.g. BNM800M, etc. Where other products are
mentioned – e.g. Receivers, Swivels, Break-Away Valves – end-users must refer to separate Banlaw
documentation covering each product prior to their installation.
4.1 Pre-Installation Guidelines
• Any proposed installation/application/operation of the Banlaw Nozzle shall
satisfy the Specifications detailed in section 3, and other requirements within
this document. As diesel refuelling is typically conducted at elevated pressure
and flowrates, the specifications for any other parts & equipment included
within this install must also comply with the parameters (e.g. pressure,
temperature, flowrate, etc.) of the application. Failure to ensure the Nozzle
and other equipment are used strictly in accordance with their applicable
specifications will introduce potentially serious safety hazards.
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 16/ 31 PRH-REF- 70
• Ensure a Nozzle with the correct Shut-Off Setting (refer section 1.6) is being
installed. Failure to select the proper nozzle setting will increase the risk of
hazards such as;
o Overfilling and the likely internal over-pressurisation of the tank(s).
o Spillage of fuel, environmental damage, or fire.
o Premature shut-off of the Nozzle, i.e. automatic shut-off of the Nozzle
before the tank is filled.
• This Product shall only be used by competent persons, trained and/or directly
supervised in their safe and proper operation.
• The Nozzle and all other diesel dispensing and refuelling system pressure
equipment shall be rated for the process conditions, i.e. pressure, flowrate
and temperature. In the event of a “drive-away” all components – i.e. the
Nozzle, Receiver, tank inlet and diesel dispensing system - shall be subjected
to abnormally high structural load (forces) which may cause catastrophic
failure of equipment within the system and potentially serious health, safety
and environmental hazards. The consequences of a drive-away can be
reduced using a sacrificial mechanical link within the system, e.g. a Banlaw
Break-Away Valve.
4.1.1 Nozzle – Ergonomics
When designing the refuelling system, the ergonomics of the nozzle operation must
be considered to avoid potentially serious work health & safety (WHS) hazards. An
assessment of the physical handling of the Nozzle for each intended application must
be part of a pre-installation due diligence assessment. Key manual handling tasks
include;
• Carrying the Nozzle and attached fuel supply line to and from the Nozzle
storage point (e.g. Nozzle Holster) and the Receiver onboard the plant
equipment.
• Connection and disconnection of the Nozzle and Receiver, particularly at
extended reach.
• Actuation of the Nozzle operating handle, particularly at extended reach.
Additionally, to prevent damage and contaminant ingress, Nozzles should not be
dragged on the ground. This type of Nozzle abuse is particularly common in
applications that incorporate hose reels with an automatic rewind function.
The use of a Banlaw Swivel at the Nozzle inlet is recommended to improve ergonomics, specifically to
reduce the degree of twist transferred to the Nozzle from the attached supply hose – refer Figure 15.
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 17/ 31 PRH-REF- 70
Figure 15 – Basic Nozzle and Receiver Arrangement
Figure 16 - Angled (Down) Orientation of Receiver
• The Nozzle must be aligned concentrically with the Receiver for connection.
• The Nozzle may be oriented at any angle during operation – i.e. when
connected to the Receiver.
• To improve ease of use (ergonomics);
o If the Receiver is installed at a height above (human) chest height (i.e.
above approx. 1.2m, 4’), end-users may benefit from the installation
of the Receiver in a downwards orientation – as per Figure 16.
o If the Receiver is installed at a height below (human) waist height (i.e.
below approx. 0.9m, 3’), end-users may benefit from the installation
of the Receiver in an upwards orientation – as per Figure 17.
• The overall weight of the Nozzle and attached hose and fittings should be
minimised. This objective is aided by avoiding the use of excessive fittings
between the hose outlet and nozzle inlet. The hose outlet should be
configured to attach directly into the Swivel inlet.
NOZZLE
RECEIVER
SWIVEL
FROM SUPPLY
TO TANK
RECEIVER INSTALLED AT ELEVATED HEIGHT
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 18/ 31 PRH-REF- 70
Figure 17 - Angled (Up) Orientation of Receiver
4.1.2 Nozzle – Storage
A secure means of storing the Nozzle when not in use must be provided to avoid situations where the
Nozzle is left lying on the ground, increasing the risk of contamination ingress into the Nozzle and a
potential trip hazard to personnel. This can be accomplished by installing a Banlaw Nozzle Holster or
Nozzle Anchor or by fabricating a custom bracket to safely store the Nozzle. The location of the holster
etc. shall allow safe, convenient and ergonomic access by personnel, and provide a means of stowing
the nozzle and dispensing hose in a safe location out of pedestrian and vehicle thoroughfares.
Additionally, use of a dedicated storage point be interlocked with additional safety systems to prevent
vehicle driveaway while the nozzle is still connected.
Figure 18 illustrates the use of a (“tall”) Banlaw Nozzle Holster. “Short” holsters (i.e. without the stand)
are also available for mounting onto existing raised platforms and for use on service trucks etc.
A dedicated means of securely storing a Nozzle off the ground provides several key
benefits, including;
• Minimises the ingress of contamination (dust, water, etc.) into the Nozzle -
maximising the service life of the Nozzle.
• Minimises the risk of the Nozzle being struck or run over by vehicles in the
same area. Bollards or barriers around the area will also assist.
• Minimises trip hazards.
• Can be interlocked with additional safety features to prevent vehicle
“driveaway”.
RECEIVER INSTALLED AT LOW HEIGHT
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 19/ 31 PRH-REF- 70
Figure 18 - Nozzle Stored in Nozzle Holster
4.2 Installation Guidelines
Damage to the cast housing of the Nozzle can occur if the 2” NPT (M) fitting (i.e. Swivel outlet) is over-
tightened into the Nozzle inlet. With appropriate thread sealant, the 2” NPT threaded connection
should be tightened to approximately 1.5 to 2 turns (i.e. 5mm, 13/64”) past hand-tight engagement.
I.e. NPT threads are tightened according to the length of thread engagement, not a torque.
General Installation Notes;
1. Conduct a Job Hazard Analysis (JHA) prior to install to mitigate health,
environmental and equipment hazards.
2. Do NOT install any parts that are damaged or are otherwise faulty.
3. Do NOT install parts which are not compatible with mating parts or parts
which do not satisfy the specifications of the system.
4. Conduct all necessary measures to prevent the ingress of contamination into
the Banlaw Nozzle and other components.
5. Only engage threads of the same thread type. Ensure all threaded connections
are clean and in good condition. Avoid over-tightening.
6. An appropriate thread sealant is recommended on the 2” NPT (F) process
connection (inlet) of the Nozzle. Use sparingly and avoid excess use of Loctite
and similar products – residual thread sealants etc. may cause contamination
and malfunction of the Nozzle.
7. Use only proper hand tools for the installation of all components. Avoid the
use of power or impact tools, and adjustable wrenches (e.g. stilsons).
8. Use consumables (e.g. Loctite products) strictly in accordance with the OEM
Safety Data Sheet (SDS) and operating guidelines. Do not use consumables
beyond their expiry date.
NOZZLE HOLSTER
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 20/ 31 PRH-REF- 70
Figure 19 - Nozzle Inlet Connected
4.2.1 Banlaw FuelTrack Nozzles
This section applies to installation requirements specifically for FuelTrack series Nozzles – e.g. BNMF800
and BNF1000 series. During connection of the Swivel – refer section 4.2 - it is imperative the spring-
loaded “male” probe extending from the Swivel outlet is inserted into the “female” probe within the
Nozzle inlet.
Figure 20 shows the auto ID circuit components (i.e. hard links) connecting the FuelTrack Swivel to the
FuelTrack Nozzle inlet.
Figure 20 - Swivel Outlet and Nozzle Inlet
Once the Swivel is secured into the Nozzle, the auto ID circuit voltage available at the Nozzle outlet must
be tested using a voltmeter (or multi-meter) as per Figure 21. This test also establishes any short circuit
within the Nozzle or auto ID circuit. The positive (+) terminal is placed onto the metal Retainer at the
centre of the Nozzle outlet, and the negative (-) terminal is placed onto the exterior of the Swivel. The
voltage must be 4.6 to 5.0 Vdc. A lower voltage indicates excessive electrical resistance (i.e. low
conductivity) in the circuit – refer section 7. A lack of voltage (i.e. 0Vdc) indicates either the circuit is
isolated (de-energised) or a short circuit – refer section 7.
DO NOT
OVERTIGHTEN
SWIVEL
HOSE-TAIL
INSERT DURING CONNECTION
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 21/ 31 PRH-REF- 70
Figure 21 - Testing for Voltage and Short Circuit
4.3 Commissioning Guidelines
There are no specific commissioning requirements for a Banlaw Nozzle. Banlaw do however recommend
witnessing tank pressures and system performance during the initial refuelling process of each unique
refuelling configuration. It is especially beneficial to confirm system performance when a new nozzle is
installed, or existing refuelling system components are modified. These checks provide confirmation
that the system is configured correctly and operating within safe working parameters.
Confirmation of initial system performance will help prevent premature nozzle shut off and tank overfill.
Additionally, these checks ensure that operators do not need to manually override the shut-off
mechanism of the nozzle or are conducting other improper operating practices,
The incidence of operators who manually override the automatic tank pressure shut off function of
Banlaw Nozzles by holding the nozzle in the open position is a principal indication that the system is not
configured properly or being maintained sufficiently.
5 PRINCIPLES OF OPERATION
• A Banlaw Nozzle shall only be used by trained personnel, deemed
competent in its proper operation. The operation of a Nozzle by untrained
persons introduces potentially serious health and safety risks.
• A Banlaw Nozzle must only be operated in accordance with Banlaw
procedures.
• Any incidents or problems involving the operation of the Nozzle – and the dry-
break refuelling system – should be promptly reported and investigated.
• Equipment that is damaged, leaking or otherwise unfit for operation must not
be used, but must instead be replaced or repaired prior to use of a diesel
refuelling system.
• It is recommended the refuelling event is monitored (supervised). In the
event of a system malfunction or other incident, this will allow personnel to
react promptly to avoid further escalation of the hazards.
The use of a splash-fill adaptor (refer Figure 22) with a dry-break refuelling nozzle
introduces additional hazards and risk. Persons must not use such an adaptor without
being trained on the additional safe operating requirements for this task.
4.6≤Vdc≤5.0
SWIVEL
RETAINER
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 22/ 31 PRH-REF- 70
Banlaw Recommends “Designing Out” the requirement to refuel with such Splash-fill
adaptors wherever possible. Please refer to Banlaw document BPA-27 for further
information.
Figure 22 - Example of a Splash-Fill Adaptor
Refuelling couplings, e.g. nozzle and receiver, that are contaminated with dust and other build-up must
be cleaned prior to use. This will help prevent;
• Contamination entering the system, subsequently increasing the probability of system failure.
• Contamination from entering the fuel stream, increasing the probability of engine fuel system
problems.
• Accelerated wear & tear of mating parts.
• Damage to fluid seals, creating fuel leakage.
• Difficulty in properly engaging/connecting the nozzle and receiver.
The following list illustrates a typical operating sequence for a dry-break system refuelling system
comprising a Banlaw Nozzle. Fuel spillage should not occur during refilling of the tank(s), whether by
tank overfill or other causes.
IF A TANK LEVEL GAUGE EXISTS, FIRST DETERMINE WHETHER THE TANK(S) REQUIRES
REFILLING (I.E. FUEL LEVEL IS BELOW THE SAFE FILL LEVEL).
ENSURE NOZZLE OPERATING
HANDLE IS SECURELY LATCHED IN
THE “OFF” (CLOSED) POSITION
REMOVE NOZZLE FROM ANCHOR
OR HOLSTER. REMOVE RECEIVER
DUST CAP.
NOZZLE DISCONNECTED FROM
RECEIVER.
“OFF” (CLOSED)
RECEIVER DUST CAP REMOVED
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 23/ 31 PRH-REF- 70
RETRACT NOZZLE ACTUATOR AND
PUSH ONTO RECEIVER.
NOZZLE AWAITING CONNECTION -
ACTUATOR RETRACTED.
CONNECT NOZZLE AND RECEIVER -
ACTUATOR STILL RETRACTED.
NOZZLE AND RECEIVER CONNECTED
- ACTUATOR RELEASED &
FORWARD. RELEASE ACTUATOR
AND ALLOW IT TO RETURN
FORWARD. PULL BACK ON NOZZLE
“D” HANDLE TO CONFIRM A SECURE
CONNECTION WITH RECEIVER.
START FUEL DISPENSING PUMP
MANUALLY OPEN REFUELLING NOZZLE BY DISENGAGING T-HANDLE CATCH, THEN
MOVE HANDLE INTO THE “ON” (OPEN) POSITION. IF NOZZLE IMMEDIATELY SHUTS OFF,
MANUALLY CYCLE NOZZLE BETWEEN OPEN AND CLOSED FOR APPROX. 2-3SECS. IF
NOZZLE WILL STILL NOT REMAIN OPEN, CONFIRM TANK IS NOT ALREADY FILLED TO
CAPACITY. IF NOT, REFER SECTION 7.
DO NOT MANUALLY OR OTHERWISE FORCIBLY HOLD THE OPERATING
HANDLE IN THE ON (OR PARTIALLY ON) POSITION!
UNLATCHING OPERATING
HANDLE FROM OFF POSITION
RETRACT ACTUATOR
2. PUSH NOZZLE ONTO RECEIVER
1. ACTUATOR RETRACTED
1. RELEASE ACTUATOR
2. ACTUATOR FORWARD
HANDLE CATCH
3. PULL BACK TO CONFIRM CONNECTION
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 24/ 31 PRH-REF- 70
NOZZLE OPERATING HANDLE
IN ON POSITION
ALLOW TANK TO REFILL. IF POSSIBLE, VISUALLY MONITOR RISING FUEL LEVEL WITHIN
TANK(S).
ONCE TANK REACHES CAPACITY, THE MEANS OF TANK OVERFILL PROTECTION (OFP)
WILL TERMINATE THE INFLOW OF FUEL INTO THE TANK(S). ONCE THE DEGREE OF FUEL
PRESSURE REACHES THE SHUT-OFF PRESSURE OF THE NOZZLE, THE NOZZLE WILL
AUTOMATICALLY CLOSE. DO NOT REOPEN THE NOZZLE ONCE THE TANK IS FILLED!
ENSURE NOZZLE T-HANDLE CATCH IS LATCHED IN THE “OFF” (CLOSED) POSITION PRIOR
TO DISCONNECTION.
STOP FUEL DISPENSING PUMP.
RETRACT NOZZLE ACTUATOR AND
DISCONNECT FROM RECEIVER.
DISCONNECTING NOZZLE AND
RECEIVER - ACTUATOR RETRACTED
REPLACE RECEIVER DUST CAP AND RETURN NOZZLE TO STORAGE HOLSTER/ANCHOR.
The fluid flow path through a connected Nozzle and Receiver assembly is controlled
by the operating handle (T-Handle) of the Nozzle. Whilst the operating handle is
latched in the OFF position, the fluid path is closed. The flow path is open whenever
the handle is not latched in the OFF position, and fully open when the handle is on
the ON position. The fuel flow through the Nozzle and Receiver may be manually
controlled by the operator. The Nozzle will automatically close once the internal fluid
pressure reaches the shut-off pressure. The dry-break feature of the Nozzle will
ROTATE HANDLE
2. PULL NOZZLE OFF RECEIVER
1. ACTUATOR RETRACTED
“ON” (OPEN)
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 25/ 31 PRH-REF- 70
The list below is of common problems which may occur during the refuelling event. Each problem
introduces risk and should not be tolerated, but promptly resolved – also refer section 7.
• Premature shut-off of the Nozzle – i.e. automatic shut-off (closure) of the Nozzle prior to the
tank being filled to the required level. Premature shut-off can be resolved – for information
contact Banlaw or refer to Banlaw document EBL-33.
• Refuelling operators who manually override the automatic tank pressure shut off function of
Banlaw Nozzles by holding or using some device (i.e. O’ring) to maintain the nozzle in the open
position – e.g. refer Figure 23.
Figure 23 - Nozzle Forcibly Held "ON" (Open)
• Leakage of fuel from the Nozzle or from between the Nozzle and Receiver.
• Overfilling of the tank(s), and spillage of fuel to ground via the tank vent(s).
• Attempting to connect a Nozzle without its operating (“T”) handle latched in the OFF (closed)
position – operator training required.
• Personal injury due to poor ergonomics for Nozzle operation, e.g. difficulty connecting the
Nozzle onto the Receiver.
• The unplanned (uncontrolled) disconnection of the Nozzle from the Receiver – i.e. Nozzle “fly
off”.
• A “drive-away” – i.e. movement of the plant equipment whilst the Nozzle remains connected.
prevent the discharge of fuel from the Nozzle outlet irrespective of the position of the
operating handle.
CORD FORCIBLY HOLDING NOZZLE “ON”
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 26/ 31 PRH-REF- 70
6 MAINTENANCE & SPARE PARTS
Spare parts (including service kits) for Banlaw Nozzles are only sold to accredited Banlaw nozzle
repairers. Accredited repairers are required to use only genuine Banlaw spare parts and have been
trained by Banlaw on the safe and proper repair and testing of Banlaw Nozzles – please refer to the
Banlaw website for a list of repairers near you.
No attempt to repair a Banlaw Nozzle shall be made by untrained personnel. The
improper repair of a Banlaw Nozzle will create potentially serious health and safety
risks if the Nozzle is used. The Nozzle incorporates important safety features which
will be jeopardised by improper repair, tampering, adjustment, or modification.
Persons performing such unauthorised activity do so at their own risk.
6.1 Preventative Maintenance
Banlaw Nozzles contain relative moving parts and fluid seals which will wear after a period of normal
use. The effective working life of a Nozzle and associated refuelling equipment depend on many factors,
particularly the environment in which they operate. Dusty and dirty environments more prone to
contamination build-up in refuelling couplings and/or excessive contamination within the fuel stream
will cause accelerated wear & tear. In addition, the use of high pressure washdown water, mineralised
(hard) water, solvents and aggressive chemicals to clean a Nozzle will also cause damage and reduce
the working life of the Nozzle. Due to the many varied operating environments in which Banlaw
equipment is used, any preventative maintenance information provided within this document shall be
used a guide – unless noted otherwise.
The front end of the Nozzle is more exposed to contamination ingress and general wear & tear,
particularly if a Nozzle Anchor, Holster or Dust Plug is not used to store the Nozzle. Figure 24 illustrates
the front end of a nozzle returned to Banlaw – as received (i.e. uncleaned) - for repair. Observe the
contamination within this sensitive area of the Nozzle. Also noted are important areas and features of
the nozzle which require regular inspection for damage and excessive wear.
Figure 24 - Front End of Nozzle and Critical Items
BUMPER
BALL LOCKS
RETAINER
SLEEVE FACE SEAL
BODY (FRONT)
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 27/ 31 PRH-REF- 70
A Nozzle which is damaged to the extent its safe use and proper operation may be
jeopardised shall not be used, but instead promptly replaced and returned to Banlaw
or an authorised Banlaw Nozzle Repair Agent for repair.
The following key preventative maintenance guidelines apply to Banlaw Nozzles & Receivers;
1. Ensure adequate engineering controls are maintained to prevent exposure of a Nozzle to
elements (i.e. pressure, flowrate and temperature) outside of the Banlaw specifications (refer
section 3). Such controls will include;
a. Pressure relief for the supply line connected into a nozzle to mitigate over-
pressurisation due to thermal expansion of the liquid (fuel).
b. Fluid pressure spike (fluid hammer) controls.
c. Shields, covers etc. to protect a Nozzle from high pressure washdown water – especially
relevant on (mobile) service trucks.
2. Ensure adequate controls and condition monitoring are in place to ensure the contamination
levels (and other specifications) of your fuel supply are maintained – PREVENT inferior quality
fuel entering your site’s fuel infrastructure and plant equipment.
3. As required, install inline (bulk) filtration on all diesel dispensing lines – contact Banlaw for
advice.
4. Maintain the use of the Receiver Dust Cap and Nozzle Anchors, Holsters, or Dust Plugs.
5. Remove any contamination from the dry-break Receiver (front end) prior to connecting a Nozzle
– refer contaminated Receiver in Figure 25.
6. Prior to each use;
a. Visually inspect the Nozzle for excessive wear & tear, fuel leaks or damage.
b. Visually inspect the Receiver for excessive wear & tear or damage. Third party (non
Banlaw) Receivers manufactured from aluminium and plated steels are especially prone
to corrosion and wear & tear – refer examples in Figure 26 and Figure 27. Damaged
Receivers should not be used, as the risk of hazards such as fuel leakage and nozzle “fly
off” are increased.
Figure 25 - Contaminated Receiver - No Dust Cap Fitted
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 28/ 31 PRH-REF- 70
Figure 26 - Receiver with Excessive Wear
Figure 27 - Damaged Receiver
7. Replace a Receiver when damaged, or otherwise no later than;
a. Mining; every 3 years.
b. Rail and Light Industry; 5 years.
8. Remove a Nozzle from operation when damaged. The recommended Nozzle repair schedule is;
a. Mining; every 4-6 months.
b. Rail and Light Industry; every 12 months.
9. Use a Nozzle Holster or Nozzle Anchor to safely store a Nozzle (off the ground) when not in use.
Please contact Banlaw or your nearest Banlaw agent for more detailed preventative maintenance
information.
6.2 Banlaw Onsite Maintenance
Clients can benefit from a Banlaw Service Level Agreement (SLA) to assist in the preventative and
corrective maintenance of refuelling systems onsite, in addition to other diesel, fuels, oils and coolant
infrastructure. This support is provided for Banlaw and third-party products. Clients with an SLA can
focus on their core business activities and allow experienced Banlaw technicians and engineers to help
keep such infrastructure operating at optimum safety, performance and reliability.
WEAR TO “LOCKING” ANNULUS
DAMAGE TO FRONT CIRCUMFERENCE
DAMAGE TO FRONT FACE
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 29/ 31 PRH-REF- 70
7 TROUBLESHOOTING
This section provides troubleshooting recommendations for the range of Banlaw dry-break refuelling
Nozzles when installed, operated and maintained in accordance with Banlaw guidelines.
PROBLEM PROBABLE CAUSE AND SOLUTION
Premature
nozzle shut-off
during
refuelling.
• Increased system head pressure downstream of (after) the Receiver.
Potential causes include;
o Excessive restriction to airflow from the tank vent(s) – check
breather hoses for obstructions (e.g. mud).
o The flow control valve within the OFP system is throttling the
flow or faulty – investigate.
o Premature operation of the OFP system – wait for fuel in the
tank(s) to settle and restart refuelling.
• Nozzle spring setting too “low” (light) for application. Contact Banlaw or
your nearest Banlaw agent for advice.
• Receiver spring setting to high (heavy) for application. Contact Banlaw or
your nearest Banlaw agent for advice.
• Nozzle flow rate above recommended maximum. Reduce delivery flow
rate.
• Nozzle flow rate below recommended minimum. Increase delivery flow
rate.
• Excessive free-play (mechanical wear) in the Nozzles operating
mechanism - replace Nozzle and have faulty Nozzle serviced.
• A component in the system has been replaced with a component which
causes increased flow restriction – investigate and return system to the
previous state.
• Faulty Level Sensor - replace Level Sensor.
• Faulty Flow Control Valve - replace Flow Control Valve.
• Faulty Nozzle - replace Nozzle and have faulty Nozzle serviced.
• A foreign object is caught within the Nozzle and/or Receiver –
investigate.
Refuelling
operators
manually
overriding the
automatic tank
pressure shut
off function of
the Nozzle
• Consult with operators to locate the specific offending refuelling
applications - investigate root cause(s) and rectify.
• Confirm appropriate design and configuration of refuelling systems on
site – standardise as far as practicable the refuelling equipment on plant
equipment of similar configurations.
• Provide training to refuelling operators stressing importance of the risks
associated with overriding the automatic shut-off function of a Nozzle.
Tank overfilling • If fitted, the primary “zero tank pressure” OFP system is faulty –
investigate and rectify.
• If using the “pressurised tank” feature of the dry-break refuelling system
as a means of OFP;
o Faulty (i.e. leaking) tank vent(s) – replace vent(s).
o Fuel and/or air leakage from tank(s) after closure of the vent(s)
– identify source of leakage and effectively seal (e.g. leaking
manual filler point cap).
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PROBLEM PROBABLE CAUSE AND SOLUTION
• Nozzle or OFP system flow rate outside the recommended range.
Maintain flowrate within the recommended minimum and maximum
range.
• Nozzle operating handle being forcibly held in the ON (open) position
during refuelling – assess root cause(s) and rectify.
• Nozzle is reopened after the tank is filled – train operator(s) on correct
nozzle operation.
• Nozzle spring setting too “high” (heavy) for application. Contact Banlaw
or your nearest Banlaw agent for advice.
• Vent pressure relief spring setting below Nozzle and Receiver shutoff
value. Contact Banlaw or your nearest Banlaw agent for advice.
Fluid Leakage
from Nozzle
• Faulty fluid seal(s) within Nozzle – replace Nozzle and have faulty Nozzle
serviced.
• Over-pressurisation of Nozzle – maintain fluid pressure under the SWP.
• Temperature below minimum operating temperature of the Nozzle –
replace Nozzle with a Banlaw “arctic” series Nozzle.
• A foreign object is caught within the Nozzle – investigate.
• Fuel overly contaminated – investigate and rectify.
Fluid Leakage
between Nozzle
and Receiver
during
Refuelling
• Faulty fluid seal(s) within Nozzle – replace Nozzle and have faulty Nozzle
serviced.
• Sealing surfaces on Receiver are damaged – replace Receiver.
• Contamination (dirt, mud etc.) build-up within Nozzle – clean Nozzle and
Receiver or replace Nozzle and have faulty Nozzle serviced. Ensure
Receiver Dust Caps and a Nozzle Holster or Anchor are used.
• Fuel overly contaminated – investigate and rectify.
• Temperature below minimum operating temperature of the Nozzle –
replace Nozzle with a Banlaw “arctic” series Nozzle.
Nozzle
Uncouples from
Receiver During
Refuelling
• Incorrect combination of Nozzle and Receiver. Confirm compatibility.
Only use the correct combination of Nozzle and Receiver.
• Worn ball lock mechanism on Nozzle and/or Receiver. Inspect both
equipment and replace if necessary.
• Contamination within ball lock groove on receiver body. Clean
thoroughly and reconnect nozzle.
• Nozzle improperly coupled to Receiver. Try again.
No fuel flow
through Nozzle
• Valve upstream or downstream within system is closed – investigate.
• Banlaw FuelTrack receiver ID tag (code) has not been entered into the
onsite FMS database and/or properly configured within the database.
• FuelTrack receiver ID tag has not been received by local FMS depot;
o Existing fault with auto ID dry-break system, e.g. short circuit or
under-voltage – investigate and rectify.
o Faulty auto ID chip in receiver – install new Banlaw FuelTrack
Receiver.
o Turn Nozzle on (open) and verify ID code is read.
o Contact your onsite FMS “champion” or Banlaw Helpdesk.
Banlaw
FuelTrack (or
ResTrack) Auto
• System power supply has been cut (isolated) – investigate and rectify.
BANLAW PRODUCT DATA SHEET DRY-BREAK DIESEL REFUELLING NOZZLES
Version 1.0 31/ 31 PRH-REF- 70
PROBLEM PROBABLE CAUSE AND SOLUTION
ID System
Inoperable
• Short circuit or open circuit in the auto ID circuit. Test voltage available
at Nozzle – refer section 0. If no voltage, fault find circuit until problem
is resolved. Contact your onsite FMS “champion” for assistance.
Nozzle cannot
be connected or
disconnected
from Receiver
• Nozzle operating (“T”) Handle not latched in “OFF” (closed) position.
Only attempt to connect or disconnect a Nozzle with its operating Handle
latched in the “OFF” position.
• Incorrect combination of Nozzle and Receiver. Confirm compatibility.
Only use the correct combination of Nozzle and Receiver.
• Worn ball lock mechanism on Nozzle and/or Receiver. Inspect both
equipment and replace if necessary.
• Contamination within ball lock groove on receiver body. Clean
thoroughly and reconnect nozzle.
8 PRODUCT RECYCLING & DISPOSAL
Banlaw Nozzles are fully serviceable, providing extended working lives and the more responsible use
of resources.
Banlaw values and supports the sustainable use of resources, and the safe, responsible and proper
disposal or recycling of all materials within its products. For a description of the principal materials
within a Banlaw Nozzle, please refer to section 3.
9 PRODUCT WARRANTY
Banlaw is committed to providing quality products and services. To provide further assurance, our
products and services are backed by generous warranties.
A copy of the Banlaw product warranty terms and conditions is available from Banlaw, the Banlaw
website, or your nearest authorised Banlaw agent.
END OF DOCUMENT
Website – www.banlaw.com